Beverage delivery pod and method of use and manufacture

ABSTRACT

A pod containing one or more beverage ingredients is provided, where the pod comprises a generally rigid outer member ( 12 ) with an open top and an outlet opening in the bottom, with an internal filter ( 16 ) adjacent a bottom portion of the outer member, one or more beverage ingredients disposed above the filter, and a lid ( 14 ) closing the open top. The outer member has an outer peripheral sidewall ( 20 ) defining the open top and extending downwardly from the open top toward the bottom portion and inwardly converging toward the outlet opening. The bottom portion of the sidewall defines a plurality of ribs ( 36 ) extending inwardly in the interior of the outer member toward the outlet opening. Beverage outlet flow paths are disposed between adjacent ribs and directed toward the outlet opening. The filter is supported above the outlet opening and the beverage outlet flow paths by the ribs.

FIELD

A beverage delivery pod is described herein and, in particular, a sealedbeverage delivery pod containing one or more ingredients for thepreparation of beverages.

BACKGROUND

Single serve beverage brewing systems can have a brewing machineconfigured to receive a filtered pod containing a single serving portionof one or more beverage ingredients, such as coffee or tea. The brewingmachine can be configured in pass heated water through the pod to formand dispense a beverage therefrom. A machine can be configured to piercethe top of the pod to inject water into the pod, as well as to piercethe bottom of the pod to permit the beverage to exit the pod. Thepiercing of the pods for both the injection of water and the exiting ofthe beverage may not be desirable for all applications.

Beverage pods can be constructed from a variety of different materialsand in a variety of different manners, not all of which lead tocost-effective manufacture and disposal and not all of which aresuitable for use in different beverage brewing systems. Some beveragepods, for example, can require complex manipulations of internalelements during assembly. Other beverage pods can require complicatedinternal, injection molded components. Beverage pods are also known tobe made with materials that can undesirably add to their cost.

SUMMARY

A pod containing one or more beverage ingredients is provided, where thepod comprises a generally rigid outer member with an open top and anoutlet opening in the bottom, with an internal filter adjacent a bottomportion of the outer member, one or more beverage ingredients disposedabove the filter, and a lid closing the open top. The outer member hasan outer peripheral sidewall, which can be generally annular, definingthe open top and extending downwardly from the open top toward thebottom portion and inwardly converging toward the outlet opening. Thebottom portion of the sidewall defines a plurality of ribs extendinginwardly in the interior of the outer member toward the outlet opening.Beverage outlet flow paths are disposed between adjacent ribs anddirected toward the outlet opening. The filter, which may besubstantially planer, is supported above the outlet opening and thebeverage outlet flow paths by the ribs.

In order to facilitate attachment of the filter, the sidewall includesan inward step about its periphery substantially coplanar with a topsurface portion of the ribs to define an attachment surface to which thefilter can be attached, such as by using an adhesive or by welding.While a large attachment surface can simplify attachment of the filter,if too large then more area of filter will be blocked, therebydecreasing the free flow area. In one aspect, the filter attached to theattachment surface has a ratio of free flow area to blocked flow area ofbetween about 3:1 and 4:1, more preferably between about 3.2:1 and3.7:1, and even more preferably about 3.4:1.

To increase the surface area of the filter, including the free flowarea, the filter may be in a conical, including truncated conical,configuration, whether facing upwardly or downwardly. This can beaccomplished by configuring the top surface portions of the ribs toextend inwardly toward the outlet opening at an inclination such thatthe area of the attachment surface is larger than if the top surfaces ofthe ribs, and the filter thereon, were precisely coplanar.

The bottom portion of the sidewall can have a semi-circular ordome-shaped profile, which can be defined at least in part bycurvilinear bottom walls of the outlet flow paths. The outlet flow pathscan also be bounded by upstanding, interior sidewall segments disposedon opposite sides of each of the bottom walls. Those same sidewallsegments can also form sidewall segments of the adjacent ribs.

The bottom portion of the sidewall, including if it is semi-circular ordome-shaped in profile, can be configured such that, in use, the pod isat least partially received in a brewing compartment of a beveragebrewing device in a position for dispensing a beverage where the bottomportion of the sidewall is spaced from an upstanding piercing element ofthe brewing compartment. That is, the bottom portion of the sidewalldoes not have to be pierced to dispense a beverage. In one aspect, theheight of the bottom portion is between about 20% and 30% of the totalheight of the pod, and more preferably about 25% of the total height ofthe pod. In another aspect, the outlet opening can be surrounded by asubstantially planar segment of the sidewall. A ratio between thediameter of the substantially planar segment to a maximum diameter ofsidewall adjacent the beverage ingredient compartment can be betweenabout 1:3.7 and 1:4.7.

The materials used to form the beverage delivery pod can be selected tofacilitate economical manufacture and/or recyclability. In one aspect,the lid can be formed on a non-metallic, multi-layer film. By omittingthe metallic layer, the lid can more readily be removed from the outermember to empty remaining beverage ingredients after use and recycle thelid and/or the outer member. In another aspect, the outer member can beformed of a corn-based, biodegradable material. In yet another aspect,the lid and/or the outer member can be formed of materials lackingenhanced barrier properties. Instead, one or more pods can be providedwithin outer packaging, such as a flexible wrapper, which can providegreater barrier properties, as compared to the barrier properties of thelid and/or outer member of the pod.

A method of dispensing a beverage made from the beverage ingredients inany of the pods described herein is also provided. The method includesinserting the pod into a brew compartment of a beverage brewing device,forming an opening in the lid, and injecting an aqueous medium into thebeverage ingredient compartment of the pod through the opening in thelid whereby the aqueous medium interacts with the one or more beverageingredients to form a beverage. The method further includes filteringthe beverage through the filter followed by dispensing the beverage fromthe beverage delivery pod through the outlet opening. The methodincludes optionally providing the pod with the outlet opening in anunblocked configuration prior to the step of inserting it into the brewcompartment, such that a resultant beverage can exit the pod withoutrequiring the bottom portion of the outer member to be pierced.

A method of manufacturing any of the beverage delivery pods describedherein is also provided. The method can include providing the outermember, inserting the filter into the outer member, attaching the filterto the ribs in the bottom portion of the outer member and to at leastsubstantially a peripheral portion of the sidewall surrounding the ribs,depositing the one or more beverage ingredients into the outer memberabove the filter, and attaching the lid to the outer member above theone or more beverage ingredients to close the beverage ingredientcompartment.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side elevation view of a beverage delivery pod, showing anouter member with an attached lid;

FIG. 2 is an exploded perspective view of the beverage delivery pod ofFIG. 1, showing the lid, an internal filter and the outer member, withthe beverage ingredient omitted;

FIG. 3 is a perspective view of the outer member of the beveragedelivery pod of FIG. 1, showing inwardly extending, raised ribs in theinterior of a bottom portion of the outer member with outlet flow pathstherebetween directed toward an outlet opening;

FIG. 4 is a top plan view of the outer member of the beverage deliverypod of FIG. 1;

FIG. 5 is a cross-sectional elevation view of the beverage delivery podof FIG. 1, taken along line 5-5 as indicated on FIG. 4 (with the lid,beverage ingredient, and filter omitted for clarity) and showing thelid, beverage ingredient, filter and curvilinear walls defining in partthe outlet flow paths;

FIG. 6 is a cross-sectional elevation view of the beverage delivery podof FIG. 1, taken along line 6-6 as indicated on FIG. 4 (with the lid,beverage ingredient, and filter omitted for clarity) and showing thelid, beverage ingredient, filter and ribs; and

FIG. 7 is a cross-section elevation view of the beverage delivery podsimilar to that of FIG. 5, but showing the pod disposed in a brewcompartment of a beverage brewing device and with the bottom portion ofthe outer member being spaced from a bottom piercing element of the brewcompartment.

DETAILED DESCRIPTION

The beverage delivery pod 10 generally comprises outer member 12 forcontaining one or more beverage ingredients 18, a filter 16 supported ina bottom portion of the outer member 12, and a lid 14 closing a topportion of the outer member 12, as illustrated in whole or in part inFIGS. 1-7. In use, the beverage delivery pod 10 is configured to haveits lid 14 pierced to form an opening through which an aqueous medium,typically water, is introduced. The one or more beverage ingredients canbe, for example, roast and ground coffee or leaf tea. Other exemplarybeverage ingredients include liquid coffee, chocolate or combinationsthereof. The aqueous medium mixes with the one or more beverageingredients 18 in the pod 10 to form a beverage which is passed throughthe filter 16 and dispensed through an outlet opening 34 disposed in thebottom portion of the outer member 12.

The beverage delivery pod 10 of the exemplary embodiment is configuredto permit dispensing of the beverage without requiring the outer member12 to be pierced. Instead, the beverage is permitted flow out of theoutlet opening 34 disposed in the bottom portion of the outer member 12,as depicted in FIG. 7. The beverage delivery pod 10 of the exemplaryembodiment is also configured to facilitate manufacturing, includingproviding the conical filter 16 which is supported in an elevatedposition above the outlet opening 34. The beverage delivery pod 10 ofthe exemplary embodiment is further configured to use reduced-costcomponents which can be readily recyclable.

Turning first to the configuration of the beverage delivery pod 10, theouter member 12 is generally in the shape of an annular cup, as depictedin FIGS. 1-4. The outer member 12 includes an outer sidewall 20 whichforms the radially-outward boundary of the beverage delivery pod 10 aswell as the bottom portion thereof. The sidewall includes a peripheralflange 22 extending radially outward from a top edge of an upper segment26 of the sidewall 20, as depicted in FIG. 1, and surrounding an opentop of the pod 10. The peripheral flange 22 provides a surface againstwhich the perimeter portion of the lid 14 is sealed. The diameter isreduced at an inwardly extending upper step 28 positioned at a loweredge of the upper segment 26 of the sidewall 20. A middle segment 30 ofthe sidewall 20 extends downwardly from a radially-inward edge of theupper step 28 to an outward edge of a lower step 32. The lower step 32is at the transition of the sidewall 20 from the middle segment 30 to alower, dome-shaped bottom portion 24 which represents the bottom of theouter member 12.

Both the upper segment 26, middle segment 30 and the bottom portion 24are continuously tapered inwardly, with the taper of the upper andmiddle segments 26 and 30 being substantially constant and the taper ofthe bottom portion 24 increasing, such that the diameter of the outermember 12 and thus the pod 10 decreases from top to bottom. Such atapered configuration can facilitate withdrawal of the outer member 12from a mold during formation, as well as facilitating insertion andlocation within a beverage machine. The steps 28 and 32 can function toincrease the hoop strength of the outer member 12, thereby permittingthe thickness and therefore the amount of material used to form theouter member 12 to be minimized. One or both of the steps 28 and 32 canalso facilitate location and support during filling operations.

The bottom portion 24 of the sidewall 20 of the outer member 12 includesa plurality of raised, inwardly extending ribs 36, as depicted in FIGS.2-4. The ribs 36 surround the outlet opening 34, as depicted in FIG. 4.Disposed between the ribs 36 are flow channels which define at least inpart outlet flow paths through which, in use, the beverage can passthrough downstream of the filter 16 during flow toward the outletopening 34. The ribs 36 and interspersed flow channels are withreference to the interior of the outer member 12. When viewed from theexterior, the ribs 36 appear to be grooves and the boundaries of theflow channels appear to be protruding elements separated by the grooves.Although six ribs 36 and flow channels are depicted in the figures,other numbers could be used, such as two or preferably three or moreribs and a corresponding number of flow channels.

The ribs 36 begin at an inward edge of the lower step 32 and are eachdefined by a pair of inwardly extending sidewall segments 40 and aninward front wall 42, as depicted in FIG. 4. Each of the ribs 38 alsohas a substantially planar top surface 44. The top surfaces 44 of theribs 36 are substantially coplanar with the inner-facing surface of thelower step 32, such that the inner-facing surface of the lower step 32forms a ring around the ribs 36, for purposes that will be describedbelow.

The flow channels also begin at the inward edge of the lower step 32 andare each bounded on their bottom by a curvilinear bottom wall 38 and ontheir sides by the same sidewall segments 40 as define adjacent ribs 36.The curvilinear bottom walls 38 function to guide the beverage passingthrough the filter toward the outlet opening 34 is a generally smoothmanner, e.g., free of obstructions or changes in direction of flow. Theflow channels are each directed to a common space disposed about theoutlet opening 34, where the flows can collide and combine to form oneor more streams of beverage exiting the outlet opening 34, asillustrated in FIG. 7. Ones of the curvilinear bottom walls 38 combineto provide the dome-shaped appearance of the bottom portion 24 of thesidewall 20 of the outer member 12, such as when viewed in sideelevation, as depicted in FIG. 1.

The inner-facing surface of the lower step 32 and the top surfaces 44 ofthe ribs 36 cooperate to form a substantially flat surface to which thefilter 16 can be adhered. At least part of the substantially flatsurface acts as an attachment surface, which is the portion to which thefilter 16 is attached in a manner that impedes flow through the filterat the attachment surface. The adherence can be accomplished using anadhesive, welding or other suitable ways of attachment. The attachmentto the inner-facing surface of the lower step 32 is preferablysubstantially continuous, and more preferably completely continuous, sothat most if not all of the beverage has to pass through the filter 16before exiting through the outlet opening 34. The top surfaces 44 of theribs 36 can help to support the filter 16 in an elevated position abovethe outlet opening 34 to provide a sufficiently dispersed area of thefilter 16 such that the beverage passes through more of the unattachedsurface area of the filter 16 as opposed to being highly concentrated ina region immediately above or adjacent to the outlet opening 34, ascould result if the filter were unsupported inwardly of the lower step32. However, the attachment surface can block fluid flow through theimmediately adjacent portion of the filter 16. This attachment surfaceis preferably minimized to a degree such that there still remains thevast majority of the surface area of the filter 16 free from attachment,i.e., unblocked by the attachment surface, while still providing forsufficient support to maintain the filter 16 in its elevated positionduring the pressurization and filtration during dispensing of abeverage. In a preferred embodiment, the filter 16 has a ratio of freeflow area to blocked flow area of between about 3:1 and 4:1, morepreferably between about 3.2:1 and 3.7:1, and even more preferably about3.4:1. A larger unblocked surface area can result in reduced pressurerequirements for forcing the beverage through the filter.

In order to increase the unblocked surface area of the filter 16, thefilter 16 can be in a conical arrangement. That is, the center portionof the filter 16 is not precisely coplanar with the outer peripherythereof, but could be conical, including truncated conical, in shape.For example, the filter 16 can have an angle of inclination toward itscenter portion of between about 10 and 15 or 20 degrees, more preferablybetween about 20 and 40 degrees, and, in an exemplary embodiment, evenmore preferably about 30 degrees. The filter 16 could have a height lessthan its diameter. For instance, an angle of inclination of 30 degreesin a filter having a diameter of 37 mm can increase the total area ofthe filter 16 from 1007 mm² if precisely planar to 1165 mm². While theconical shape can either be directed upwardly or downwardly to increasethe surface area, it is preferred that the conical shape of the filter16 be directed downwardly toward the outlet opening 34. The filter couldalternatively be substantially planar.

In order to achieve the conical shape of the filter 16, the top surfaces44 of the ribs 36 can be slightly inclined, either upwardly ordownwardly, at the same or generally the same angle of inclination as isdesired for the filter 16. Furthermore, the top surfaces 44 of the ribs36 can be inwardly tapered or narrowed such that there is lesser supportor blocked surface area of the filter 16 toward its center portion,which is where the beverage will tend to exit.

Turning now to details of the material and construction of thecomponents of the beverage delivery pod 10, the outer member 12 in theexemplary embodiment is of thin walled, generally rigid construction. Bygenerally rigid, what is meant is that the structure has the ability togenerally retain its respective shape during normal handling, and ifdeformed will tend to return toward its original shape. The outer member12 is preferably formed of a biodegradable polymer material, such as acorn-based material. Suitable materials include degradable polyethylene(for example, SPITEK supplied by Symphony Environmental, Borehamwood,United Kingdom), biodegradable polyester amide (for example, BAK 1095supplied by Symphony Environmental), poly lactic acids (PLA supplied byCargill, Minn., USA), starch-based polymers, cellulose derivatives andpolypeptides.

The filter 16 is preferably made from a material with a high wetstrength, for example a non-woven fibre material of polyester. Othermaterials which may be used include a water-impermeable cellulosicmaterial, such as a cellulosic material comprising woven paper fibres.The woven paper fibres may be admixed with fibres of polypropylene,polyvinyl chloride and/or polyethylene. The incorporation of theseplastic materials into the cellulosic material renders the cellulosicmaterial heat-sealable to the surface portions 44 of the ribs 36 and theinner-facing surface of the lower step 32. The filter 16 may also betreated or coated with a material which is activated by heat and/orpressure so that it can be sealed to the attachment surfaces.

The lid 14 is preferably a multi-layer film, made from one or morepolypropylene (PP) or filled polypropylene layers and a polyethyleneterephthalate (PET) layer. In one example, the lid 14 can have thefollowing layers: PP (about 25 microns), filled PP (about 60 microns),PP (about 25 microns) and PET (about 23 microns). Preferably, though notnecessarily, the lid 14 is free of metallic layers, such as an aluminumfoil layer. This can permit the lid 14 to be more readily removed fromattachment to the flange 22 of the sidewall 20 of the outer member 12without leaving metallic remnants behind. This can permit the lid 14 tobe removed from the outer member 12 after use, the contents dumped orotherwise removed, and the outer member 12 ready to be recycled.

Both the lid 14 and the outer member 12 can lack traditional barrierlayers. Elimination of the barrier layers can reduce the costs of thecomponents. In order to provide the barrier properties for suitableshelf life of the beverage delivery pods 10, outer packaging for one orgroups of two or more of the pods 10 can be provided, such as an outerwrapper, which may be in the form of a flow wrapped film.

The beverage delivery pod 10 can be configured for use in a beveragebrewing device having a brew compartment 100 defined by an outer wall104, as illustrated in FIG. 7. The peripheral flange 22 of the outermember 12 of the pod 10 can be supported on an upper part 102 of theouter wall 104 of the brew compartment 100. The pod 10 can be configuredsuch that it is not pierced by a bottom piercing member 110 of a bottomwall 106 of the compartment 100 when fully inserted to a degreesufficient for brewing. The outlet opening 34 of the bottom part 24 ofthe sidewall 20 of the outer member 12 is preferably open, e.g., it doesnot require piercing. While it can be completely open, it also can beinitially closed, such as with a label that can be removed prior toinsertion in the brew compartment 100 or a dissolvable plug disposed inthe pod 10 to block the outlet opening 34 until dissolved by thedispensing beverage, heat or other present, non-mechanical factors.

A method of dispensing a beverage made from the beverage ingredients inany of the pods described herein is also provided. The method includesinserting the pod 10 into a brew compartment 100 of a beverage brewingdevice, forming an opening in the lid 14, such as by using an inletpiercer 112, and injecting an aqueous medium into the beverageingredient compartment of the pod 10 through the opening in the lid 14and the inlet piercer 112, whereby the aqueous medium interacts with theone or more beverage ingredients 18 to form a beverage. The methodfurther includes filtering the beverage through the filter 16 followedby dispensing the beverage from the beverage delivery pod 16 through theoutlet opening 34 and into the brew compartment 100, and from the brewcompartment 100 through an outlet 108 thereof. The method includesoptionally providing the pod 10 with the outlet opening 34 in anunblocked configuration prior to the step of inserting it into the brewcompartment 100, such that a resultant beverage can exit the pod 10without requiring the bottom portion of the outer member 12 to bepierced, such as by a piercer 110 associated with the bottom 106 of thebrew compartment 100.

A method of manufacturing any of the beverage delivery pods 10 describedherein is also provided. The method can include providing the outermember 12, inserting the filter 16 into the outer member 12, attachingthe filter 16 to the ribs 36 in the bottom portion of the outer memberand to at least substantially a peripheral portion of the inner-facingsurface of the lower step 32 surrounding the ribs 36, depositing the oneor more beverage ingredients 18 into the outer member 12 above thefilter 16, and attaching the lid 14 to the outer member 12 above the oneor more beverage ingredients 18 to close the beverage ingredientcompartment.

From the foregoing, it will be appreciated that beverage delivery pods,methods of use and methods of manufacture are provided. However,numerous modifications and variations could be made thereto by thoseskilled in the art without departing from the scope of the descriptionherein and as set forth in the claims.

1-15. (canceled)
 16. A beverage pod apparatus comprising: a beverage podcomprising: a generally rigid outer member including an upper open top;a filter in an interior of the outer member; a lid attached to the outermember to close the open top and form a beverage ingredient compartment,the beverage ingredient compartment being bounded at an upper endthereof by the lid and at a lower end thereof by the filter; at leastone beverage ingredient in the beverage ingredient compartment; the lidbeing pierceable to accommodate an inflow of an aqueous medium into thebeverage ingredient compartment; and a lower opening of the outer memberdownstream of the beverage ingredient compartment, the lower openinghaving an unblocked configuration that permits beverage to flow out ofthe beverage pod; and a flexible wrapper having barrier propertiescontaining the beverage pod.
 17. The beverage pod apparatus of claim 16wherein the flexible wrapper has greater barrier properties than atleast one of the outer member and the lid.
 18. The beverage podapparatus of claim 17 wherein the flexible wrapper has greater barrierproperties than both the outer member and the lid.
 19. The beverage podapparatus of claim 16 wherein the outer member includes a bottom portiondefining the lower opening and the bottom portion is configured suchthat, in use, the beverage pod is at least partially received in a brewcompartment of a beverage brewing device in a position for dispensing abeverage where the bottom portion of the outer member is spaced from anupstanding piercing element of the brewing compartment.
 20. The beveragepod apparatus of claim 19 wherein the bottom portion of the outer memberincludes a planar annular segment surrounding the lower opening.
 21. Thebeverage pod apparatus of claim 16 wherein the flexible wrapper includesflow wrapped film.
 22. The beverage pod apparatus of claim 16 whereinthe filter includes woven fibers or non-woven fibers.
 23. The beveragepod apparatus of claim 16 wherein the outer member includes a side wallextending downwardly from the open top toward the lower opening, theside wall including a bottom portion that converges inwardly to thelower opening.
 24. The beverage pod apparatus of claim 23 wherein thebottom portion has a dome-shaped profile.
 25. The beverage pod apparatusof claim 23 wherein the bottom portion of the side wall defines aplurality of ribs extending inwardly in the interior of the outermember, the ribs supporting the filter in the outer member.
 26. A methodof dispensing a beverage, the method comprising: removing a beverage podincluding a lower opening in an unblocked configuration from a flexiblewrapper; inserting the beverage pod into a brew compartment of abeverage brewing device; forming an opening in an upper lid of thebeverage pod; injecting an aqueous medium through the opening in the lidand into a beverage ingredient compartment of the beverage pod boundedat an upper end of the beverage ingredient compartment by the lid andbounded at a lower end of the beverage ingredient compartment by thefilter, whereby the aqueous medium interacts with at least one beverageingredient in the beverage ingredient compartment; and dispensingbeverage from the beverage pod through the lower opening in theunblocked configuration thereof.
 27. The method of claim 26 whereininserting the beverage pod into the brew compartment of the beveragebrewing device includes positioning the beverage pod in the brewcompartment without contacting the beverage pod with an outlet piercerof the beverage brewing device.
 28. The method of claim 26 whereininserting the beverage pod into the brew compartment of the beveragebrewing device includes positioning a bottom portion of the beverage podspaced from an outlet piercer of the brew compartment of the beveragebrewing device.
 29. The method of claim 26 wherein removing the beveragepod from the flexible wrapper includes removing the beverage podincluding a generally rigid outer member that defines the lower openingfrom the flexible wrapper.
 30. The method of claim 26 wherein dispensingbeverage from the beverage pod through the lower opening includesdirecting beverage through an outlet opening of the brew compartmentspaced from an outlet piercer of the brew compartment.
 31. The method ofclaim 26 wherein forming the opening in the upper lid of the beveragepod includes forming the opening in the upper lid using an inlet piercerof the beverage brewing device.